Volkswagen Jetta 2005 User Manual
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Service
Workshop Manual
Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸
Engine ID
Edition 09.2005
BHY
Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
24 - Mixture preparation, Injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg SAR5R025020
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Assembly overview - Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Checking pistons, piston rings and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Colour identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.1 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.6 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.7 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.2 Assembly overview - Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3 Assembly overview - Oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1 Assembly overview - parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Assembly overview - parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.5 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.6 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 75
Contents i
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.8 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.3 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Repairing fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 88
2.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.3 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.5 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3 Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.2 Assembly overview - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.3 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Active charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2 Assembly overview - active charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.5 Dismantling and assembling intake manifold - upper part . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.6 Dismantling and assembling intake manifold - lower part . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.7 Fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.8 Dismantling and assembling air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.9 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.10 Removing and installing fuel rail with intake manifold flaps . . . . . . . . . . . . . . . . . . . . . . . . 114
1.11 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.12 Renewing Teflon seal on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.13 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.1 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.2 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1 Front exhaust pipe and catalytic converter with attachments . . . . . . . . . . . . . . . . . . . . . . . . 125
1.2 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.3 Separating middle and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.4 Aligning exhaust system stress free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
ii Contents
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
1.3 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.4 Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Contents iii
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
iv Contents
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4-cylinder injection engine, 2005▸ - Edition 09.2005
00 – Technical data
1 Technical data
Engine number ⇒ page 1 .
Engine data ⇒ page 1 .
1.1 Engine number
The engine number (“engine code” and “serial number”) can be
found at the front on the joint between engine and gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
The engine code is also included on the vehicle data sticker.
Golf - Jetta 2005 ➤
1.2 Engine data
Engine code BHY
Displacement cc 1984
Output kW at rpm 85/5200
Torque Nm at rpm 175/4000
Bore ∅ mm 82.5
Stroke mm 92.8
Compression ratio 10.5
RON min. Coast 95 unleaded
Injection, ignition Bosch ME 7.5.1
Knock control yes
Self-diagnosis yes
Lambda regulation yes
Catalytic converter yes
Exhaust gas recirculation no
Turbocharging/supercharging no
Electronic power control yes
Inland 91 unleaded
1. Technical data 1
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
10 – Removing and installing engine
1 Removing and installing engine
Special tools and workshop
equipment required
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Engine-/gearbox jack -
V.A.G 1383/A-
♦ Pliers -VAS 5024/A-
♦ Step ladder -VAS 5085-
♦ Engine bracket -T10012-
♦ Cable ties
Removing engine ⇒ page 2 .
Securing engine to assembly stand ⇒ page 7 .
Installing engine ⇒ page 8 .
Assembly mountings ⇒ page 10 .
1.1 Removing engine
Securing engine to assembly stand ⇒ page 7 .
2 Rep. Gr.10 - Removing and installing engine
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4-cylinder injection engine, 2005▸ - Edition 09.2005
Note
♦
Before carrying out further work, disconnect battery earth
strap. First check whether a coded radio is fitted. Obtain radio
code first if necessary.
♦
The engine is removed downwards together with the gearbox.
♦
All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all types of lines (e.g. for fuel, hydraulics, active
charcoal filter system, coolant, refrigerant, brake fluid and
vacuum) and electrical wiring in their original positions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
– Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery.
– Remove engine cover.
– Remove air filter housing with connecting hoses.
Golf - Jetta 2005 ➤
1. Removing and installing engine 3
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
– Remove battery and battery tray -arrows-.
– Remove top part of intake manifold.
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Plenum chamber bulkhead.
– Detach connectors from the following components:
♦ Ignition transformer -N152-
♦ Injector for cylinder 1 -N30-
♦ Injector for cylinder 2 -N31-
♦ Injector for cylinder 3 -N32-
♦ Injector for cylinder 4 -N33-
♦ Coolant temperature sender -G62-
♦ Engine speed sender -G28-
♦ Knock sensor 1 -G61-
♦ Knock sensor 2 -G66-
♦ Secondary air pump motor -V101-
♦ Oil pressure switch -F1-
♦ Throttle valve control module -J338-
♦ If necessary A/C system shutoff thermal switch -F163-
– Pull engine wiring harness connector off engine control unit.
– Separate all connectors between engine wiring harness and
body and lay engine wiring harness on engine.
WARNING
The fuel supply line is under pressure! Wear protective glasses
and clothing to avoid injuries and skin contact. Before loosen‐
ing hose connections, wrap a cloth around the connection.
Then release pressure by carefully pulling hose off connection.
– Disconnect breather line -1-and fuel supply line -2-.
– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. Gr. 50 ; Body front; Noise insulation.
– Bring lock carrier into service position ⇒ General body repairs;
Rep. Gr. 50 ; Body front; Lock carrier service position .
– Drain coolant ⇒ page 69 .
– Remove left wheel housing liner.
4 Rep. Gr.10 - Removing and installing engine
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4-cylinder injection engine, 2005▸ - Edition 09.2005
– Unbolt heat shield for right-hand drive shaft -arrows-.
– Remove right drive shaft and then left drive shaft at gearbox
⇒ Running gear, axles, steering; Rep. Gr. 40 ; Removing and
installing drive shaft .
– Remove securing nuts -arrows- for front exhaust pipe/exhaust
manifold and pull front exhaust pipe off exhaust manifold.
– Remove bolts -1, 2 and 3- and remove pendulum support.
– Pull off or disconnect all other electrical connections from en‐
gine and gearbox as necessary and lay to side.
– Separate all connection, coolant, vacuum and intake hoses
from engine.
Vehicles with air conditioning
Golf - Jetta 2005 ➤
Note
To prevent damage to condenser or to refrigerant pipes and ho‐
ses, ensure that pipes and hoses are not stretched, kinked or
bent.
To facilitate removing and installing engine without opening re‐
frigerant circuit:
– Remove poly V-belt ⇒ page 16 .
– Separate air conditioner compressor from compact bracket ⇒
Heating, air conditioning; Rep. Gr. 87 ; Removing and instal‐
ling compressor bracket .
– Secure air conditioner compressor to lock carrier so that re‐
frigerant lines are free of stress.
Vehicles with manual gearbox
– Remove selector mechanism from gearbox ⇒ Manual gear‐
box; Rep. Gr. 34 ; Repairing selector mechanism .
1. Removing and installing engine 5
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
– Remove strut -1-.
– Remove slave cylinder -arrows- and lay to side. Do not open
hydraulic system.
Caution
Do not operate clutch pedal after slave cylinder has been re‐
moved. This can damage the slave cylinder.
Vehicles with automatic gearbox
– Disconnect selector lever cable from gearbox ⇒ Automatic
gearbox 09G; Rep. Gr. 37 ; Repairing selector mechanism .
All vehicles (continued):
– Insert engine bracket -T10012- in engine-/gearbox jack -V.A.G
1383/A- .
– Fit engine bracket -T10012- to front of cylinder block with
M10x25/ 8.8 bolt.
– Tighten securing nut exhaust side by hand.
– Lift engine and gearbox slightly using engine-/gearbox jack -
V.A.G 1383/A- .
– From above, unbolt engine side of assembly mounting from
engine bracket -arrows-.
Note
To remove securing bolts, use stepladder -VAS 5085- .
– From above, unbolt gearbox side of assembly mounting from
gearbox bracket -arrows-.
– Carefully lower engine with gearbox.
Note
Engine and gearbox must be guided carefully when lowering to
prevent damage to the bodywork, hoses and lines.
6 Rep. Gr.10 - Removing and installing engine
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.
4-cylinder injection engine, 2005▸ - Edition 09.2005
1.1.1 Securing engine to assembly stand
Special tools and workshop
equipment required
♦ Lifting appliance -VAS
2024A-
♦ Workshop crane -VAS
6100-
♦ Engine and gearbox sup‐
port -VAS 6095-
Golf - Jetta 2005 ➤
– Secure engine on engine and gearbox support -VAS 6095- to
carry out repairs.
– Remove gearbox.
1. Removing and installing engine 7
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
– Attach lifting appliance -VAS 2024A- as follows and lift from
engine-/gearbox jack -V.A.G 1383/A- using workshop crane VAS 6100- .
Pulley end: 3rd hole in hook at position 2.
Flywheel end: 3rd hole in hook at position 8.
Caution
Use securing pins on hooks and locking pins to avoid damage
to engine and vehicle.
♦ The positions marked 1...4 on the bar must be towards the
pulley end.
♦ The holes in the hooks are counted up from the hook.
– Secure engine to engine and gearbox support -VAS 6095- .
1.2 Installing engine
Assembly mountings ⇒ page 10 .
Installation is carried out in the reverse order. When installing,
note the following:
Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all types of lines (e.g. for fuel, hydraulics, active
charcoal filter system, coolant, refrigerant, brake fluid and
vacuum) and electrical wiring in their original positions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
– Insert new dowel sleeves in cylinder block for centering engine
and gearbox.
8 Rep. Gr.10 - Removing and installing engine
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4-cylinder injection engine, 2005▸ - Edition 09.2005
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
Vehicles with manual gearbox
– Lightly grease input shaft splines with grease -G 000 100- .
– Check clutch and clutch control and install ⇒ Manual gearbox;
Rep. Gr. 30 ; Repairing clutch control .
Continuation for all vehicles
– When installing engine and gearbox assembly, ensure suffi‐
cient clearance to subframe and radiator.
– Align engine mountings tension free by shaking. If necessary,
loosen engine mounting on body.
– Install pendulum support.
Note
♦
Torque settings for engine and gearbox mountings
⇒ page 10 .
♦
Electrical connections and routing ⇒ Electrical system; Rep.
Gr. 97 .
Golf - Jetta 2005 ➤
– Install right-hand drive shaft and bolt or slot left-hand drive
shaft onto gearbox ⇒ Running gear; Rep. Gr. 40 ; Removing
and installing drive shaft .
Vehicles with manual gearbox
– Install selector mechanism and adjust mechanism if necessa‐
ry ⇒ Manual gearbox; Rep. Gr. 34 ; Repairing selector
mechanism .
– Install slave cylinder for hydraulic clutch ⇒ Manual gearbox;
Rep. Gr. 30 ; Repairing clutch mechanism; Assembly over‐
view - hydraulics .
Vehicles with automatic gearbox
– Install selector lever cable and adjust if necessary ⇒ Auto‐
matic gearbox 09G; Rep. Gr. 37 ; Repairing selector mecha‐
nism .
All vehicles (continued):
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. Gr. 87 ; Removing and installing compressor bracket .
– Install poly V-belt ⇒ page 16 .
– Install sound insulation tray ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Body front; Assembly overview .
– Install plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Plenum chamber bulkhead .
– Fill coolant system with coolant ⇒ page 71 .
– Adapt engine control unit ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051; “Guided functions” .
– Carry out road test and then read fault memory.
1. Removing and installing engine 9
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
Torque settings
Threaded connection
Torque setting
Bolts, nuts M 6 10 Nm
1.2.1 Assembly mountings
Engine assembly mounting
A1) = 20 Nm + 1/4 turn (90 °) further
B1) = 40 Nm + 1/4 turn (90 °) further
C1) = 60 Nm + 1/4 turn (90 °) further
1) Renew
Gearbox assembly mounting
A2) = 40 Nm + 1/4 turn (90 °) further
B2) = 60 Nm + 1/4 turn (90 °) further
2) Renew
Pendulum support
M 7 15 Nm
M 8 25 Nm
M 10 40 Nm
M 12 60 Nm
A3) = 40 Nm + 1/4 turn (90 °) further
B3) = 100 Nm + 1/4 turn (90 °) further
3) Renew
10 Rep. Gr.10 - Removing and installing engine
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4-cylinder injection engine, 2005▸ - Edition 09.2005
13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦
Finding metal shavings or a large quantity of small metal par‐
ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent sub‐
sequent damage, perform the following after repairs:
♦
Thoroughly clean oil channels.
♦
Renew oil spray jets.
♦
Renew oil cooler.
♦
Renew oil filter.
Assembly overview ⇒ page 12 .
Removing and installing poly V-belt ⇒ page 15 .
Golf - Jetta 2005 ➤
1. Dismantling and assembling engine 11
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
1.1 Assembly overview
Part I ⇒ page 13
Part II ⇒ page 14
12 Rep. Gr.13 - Crankshaft group
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4-cylinder injection engine, 2005▸ - Edition 09.2005
1.1.1 Part I
1 - Bolt
❑ 45 Nm
2 - Engine bracket
3 - Poly V-belt tensioner
❑ Swivel with open jaw
spanner to slacken poly
V-belt ⇒ page 15
4 - Toothed belt guard - centre
part
5 - Toothed belt guard - upper
part
6 - Nut
❑ 20 Nm
7 - Washer
8 - Tensioning roller
❑ Checking semi-auto‐
matic toothed belt ten‐
sioning roller
⇒ page 33
9 - Toothed belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
❑ Removing, installing
and tensioning
⇒ page 28
10 - Bolt
❑ 20 Nm
11 - Rear toothed belt guard
12 - O-ring
❑ Renew
13 - Coolant pump
❑ Check for ease of movement
❑ If damaged or leaking, renew complete
❑ Removing and installing ⇒ page 72
14 - Bolt
❑ 15 Nm
15 - Crankshaft belt pulley
16 - Bolt
❑
90 Nm + 1/4 turn (90 °) further
❑ Renew
❑ Threads and shoulder must be free of oil and grease
❑ Use counterhold tool -3415- to loosen and tighten
Golf - Jetta 2005 ➤
1. Dismantling and assembling engine 13
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
17 - Toothed belt guard - lower part
18 - Bolts
❑ 10 Nm
❑ Renew
19 - Pulley
❑ For aircon
20 - Poly V-belt
❑ Mark direction of rotation before removing
❑ Check for wear
❑ Do not kink
❑ Removing and installing ⇒ page 15
21 - Pulley and vibration damper
❑ Can only be installed in one position, holes are offset
❑ Note position when installing toothed belt ⇒ page 28
22 - Bolt
❑ 25 Nm
1.1.2 Part II
1 - Knock sensor 1 -G61-
❑ Gold-plated contacts
2 - Connector
❑ Knock sensor 1 -G61❑ Gold-plated contacts
❑ Do not interchange
⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
3 - Bolt
❑ 20 Nm
❑ The torque setting influ‐
ences the function of the
knock sensor
4 - Coolant pipe
5 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 57
6 - Bolt
❑ 10 Nm
7 - Bracket
❑ For ignition coil
8 - Bracket
9 - Oil filter bracket
❑ Dismantling and assem‐
bling ⇒ page 59
14 Rep. Gr.13 - Crankshaft group
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
10 - Bolt
❑
15 Nm + 1/4 turn (90 °) further
❑ Renew
11 - O-ring
❑ Renew
12 - Oil cooler
❑ Coat contact surface to oil filter bracket outside the seal with sealing paste -AMV 188 100 02❑ Ensure clearance to adjacent components
13 - Nut
❑ 25 Nm
14 - Oil filter
❑ Loosen with strap wrench
❑ Tighten by hand
❑ Observe installation instructions on oil filter
15 - Connection
16 - Bolt
❑ 15 Nm
17 - Thermostat
❑ Checking: heat thermostat in water
❑ Opening begins at approx. 86° C
❑ Opening lift min. 7 mm
❑ Removing and installing ⇒ page 74
18 - Bolt
❑ 45 Nm
19 - Compact bracket
❑ For poly V-belt tensioner, alternator and air conditioner compressor
20 - Cylinder block
❑ Removing and installing sealing flange and flywheel/drive plate
❑ Removing and installing crankshaft ⇒ page 24
❑ Dismantling and assembling pistons and conrods
21 - O-ring
❑ Renew if damaged
22 - Engine speed sender
23 - Gasket
❑ Renew
1.2 Removing and installing poly V-belt
Special tools and workshop equipment required
1. Dismantling and assembling engine 15
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
♦ Mandrel -T10060A-
1.2.1 Removing poly V-belt
– Remove right-hand insulation tray: ⇒ Rep. Gr. 50 .
– Mark direction of rotation of poly V-belt.
– Swing tensioning device in direction of -arrow- to relieve ten‐
sion on poly V-belt.
– Lock tensioning element using locking pin -T10060A- .
– Remove poly V-belt.
1.2.2 Installing poly V-belt
– Installation is carried out in the reverse sequence of removal.
16 Rep. Gr.13 - Crankshaft group
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4-cylinder injection engine, 2005▸ - Edition 09.2005
Note
♦
Before installing poly V-belt, ensure that all ancillary assem‐
blies (alternator, air conditioner compressor) are secured tight‐
ly.
♦
When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
♦
For vehicles without air conditioning, fit poly V-belt on alterna‐
tor last.
♦
For vehicles with air conditioning, fit poly V-belt on air condi‐
tioner compressor last.
After completing repairs always:
– Start engine and check belt running.
Belt drive without air conditioner compressor.
Golf - Jetta 2005 ➤
Belt drive with air conditioner compressor.
1. Dismantling and assembling engine 17
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
2 Dismantling and assembling pistons
and conrods
Gradual introduction of industrially cracked conrods.
Identification:
♦ -A- conventional conrods (smooth joining surface)
♦ -B- industrially cracked conrods (rough joining surface)
Assembly overview - Pistons and conventional conrods
⇒ page 19 .
Assembly overview - Pistons and industrially cracked conrods
⇒ page 20 .
2.1 Assembly overview - Pistons and con‐
rods
Conventional conrods ⇒ page 19 .
Industrially cracked conrods ⇒ page 20 .
18 Rep. Gr.13 - Crankshaft group
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
2.1.1 Conventional conrods
1 - Piston rings
❑ Offset gaps by 120°
❑ Remove and install us‐
ing piston ring pliers
❑ “TOP” faces towards
piston crown
❑ Checking ring gap
⇒ page 21
2 - Piston
❑ Checking ⇒ page 22
❑ Mark installation posi‐
tion and cylinder num‐
ber
❑ Arrow on piston crown
points to pulley end
❑ Oil scraper ring, 2 part
❑ Checking ring-to-groove
clearance ⇒ page 21
❑ Install using piston ring
clamp
3 - Conrod
❑ Renew as set only
❑ Mark cylinder number
-B-
❑ Installation position:
4 - Conrod bearing cap
❑ Mark cylinder number
❑ Installation position:
5 - Nuts
❑
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to 30 Nm but not further
marking -A- faces to‐
wards pulley end
-B-
marking -A- faces to‐
wards pulley end
30 Nm + 1/4 turn (90 °) further
6 - Bearing shell
❑ Note installation position
❑ Do not interchange used bearing shells
❑ Ensure retaining lug fits tightly in recess
❑ Upper bearing shell with oil drilling for piston pin lubrication
❑ Axial clearance new: 0.05...0.31 mm, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage: new: 0.01...0.06 mm, wear limit: 0.12 mm. Do not rotate crank‐
shaft when checking radial clearance
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 23
❑ Piston and cylinder dimensions ⇒ page 23
2. Dismantling and assembling pistons and conrods 19
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
8 - Conrod bolt
9 - Circlip
10 - Piston pin
❑ If difficult to remove, heat piston to 60 °C
❑ Remove and install with drift -VW 222A-
2.1.2 Industrially cracked conrods
1 - Piston rings
❑ Offset gaps by 120°
❑ Remove and install us‐
ing piston ring pliers
❑ “TOP” faces towards
piston crown
❑ Checking ring gap
⇒ page 21
❑ Checking ring-to-groove
clearance ⇒ page 21
2 - Piston
❑ Checking ⇒ page 22
❑ Mark installation posi‐
tion and cylinder num‐
ber
❑ Arrow on piston crown
points to pulley end
❑ Install using piston ring
clamp
3 - Piston pin
❑ If difficult to remove,
heat piston to 60° C
❑ Remove and install with
drift -VW 222A-
4 - Circlip
5 - Conrod
❑ With industrially
cracked bearing caps
❑ Renew as set only
❑ Mark cylinder number
-B-
❑ Installation position:
marking -A- faces to‐
wards pulley end
6 - Bearing shell
❑ Note installation position ⇒ page 22
❑ Insert bearing shells centrally
❑ Do not interchange used bearing shells
❑ Check for secure seating
❑ Axial clearance new: 0.10...0.35 mm, wear limit: 0.4 mm
❑ Check radial clearance with Plastigage: new: 0.01...00.05 mm, wear limit: 0.12 mm. Do not rotate crank‐
shaft when checking radial clearance
20 Rep. Gr.13 - Crankshaft group
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 23
❑ Piston and cylinder dimensions ⇒ page 23
8 - Conrod bearing cap
❑ Note installation position
❑ The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod
9 - Bolt
❑
30 Nm + 1/4 turn (90 °) further
❑ Torx T10
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to 30 Nm but not further
2.2 Checking pistons, piston rings and cyl‐
Checking piston ring gap
Special tools and workshop equipment required
♦ Feeler gauges
inder bores
Test sequence:
– Push ring squarely from above down to approx. 15 mm from
bottom end of cylinder.
Piston ring
Gap
New Wear limit
Compression rings (top) mm 0.15…0.35 0.8
Compression rings (bottom) mm 0.40...0.40 0.8
Oil scraper ring mm 0.20…0.70 0.9
Checking ring-to-groove clearance
Special tools and workshop equipment required
2. Dismantling and assembling pistons and conrods 21
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
♦ Feeler gauges
Clean groove before check.
Piston ring
Ring-to-groove clearance
New Wear limit
Top compression rings mm 0.04…0.075 0.15
Middle compresion rings mm 0.02...0.055 0.15
Oil scraper ring mm 0.05…0.13 0.20
Checking piston
Special tools and workshop equipment required
♦ External micrometer 75...100 mm
Measure pistons approx. 10 mm from the lower edge of skirt, at
90° to the piston pin axis.
Deviation from nominal dimension max. 0.04 mm.
Bearing shells - installation position
Bearing shell -1- with oil hole -arrow- for conrod.
Bearing shell -2- without oil hole for conrod bearing cap.
– Fit bearing shells in centre of conrod and conrod cap.
Dimension -a- must be the same on the left and right, max. devi‐
ation: 0.2 mm.
22 Rep. Gr.13 - Crankshaft group
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4-cylinder injection engine, 2005▸ - Edition 09.2005
Checking cylinder bores
Special tools and workshop equipment required
♦ Cylinder gauge 50...100 mm
♦ Measure at 3 positions both across -A- and in-line with engine
-B-
♦ Deviation from nominal dimension max. 0.08 mm
Cylinder bores must not be measured when cylinder block is
mounted on a repair stand with engine and gearbox support -VW
540- , as measurements may then be incorrect.
2.3 Piston and cylinder dimensions
Honing dimension
Basic dimension mm
1st oversize mm
4) Dimension without graphite coating (thickness 0.02 mm). The graphite coating
wears away.
Note
Piston ∅ Cylinder bore ∅
82.465 (± 0.009)
82.965
4)
4)
Golf - Jetta 2005 ➤
82.50 (+0.015 +0.005)
83.01
2. Dismantling and assembling pistons and conrods 23
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Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005
3 Removing and installing crankshaft
Note
♦
Before removing crankshaft, ensure that a suitable surface for storing crankshaft is prepared so that sender
wheel ( ⇒ Item 8 (page 24) ) does not contact anything and cannot be damaged.
♦
When working on engine, secure to repair stand using engine and gearbox support -VW 540- and supple‐
mentary kit -VW 540/1B- .
1 - Oil pump
❑ With 12 bar pressure re‐
lief valve
❑ Before installing, check
that both dowel sleeves
for centring oil pump on
cylinder block are fitted
❑ Removing and installing
⇒ page 56
2 - Bolt
❑ 15 Nm
3 - Sprocket
❑ For oil pump drive
4 - Bearing shells 1, 2, 3, 4 and
5
❑ Classification for order‐
ing spare parts
⇒ page 25
❑ For bearing cap without
oil groove
❑ For cylinder block with
oil groove
❑ Do not interchange
used bearing shells
(mark)
5 - Bolts
❑
65 Nm +90 ° (1/4turn)
further
❑ Renew
❑ Threaded along com‐
plete length
❑ Tighten crankshaft to
65 Nm when measuring
radial clearance
6 - Bearing cap
❑ Bearing cap 1: Pulley end
❑ Bearing cap 3 with recesses for thrust washers
❑ Bearing shell retaining lugs in cylinder block and bearing caps must be on the same side
7 - Bearing shell 3
❑ ⇒ Item 4 (page 24)
❑ Do not interchange used bearing shells (mark)
8 - Sender wheel
❑ Renew
24 Rep. Gr.13 - Crankshaft group
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